Manufacturing method and manufacturing apparatus of fiber reinforced composite material

Abstract

A manufacturing method and a manufacturing apparatus of a fiber reinforced composite material are provided, in which the whole fiber-based material is impregnated with a resin and a molding can be performed with high dimensional accuracy. A manufacturing method of a fiber reinforced composite material according to the present invention includes fixing a fiber-based material having a first surface to a first mold to provide an opening for the first surface; setting a second mold having a second surface such that the first surface faces the second surface through a space; filling resin into the space; and relatively moving the second mold and the first mold to bring the second surface closer to the first surface, such that the fiber-based material is impregnated with the resin.

The invention claimed is: 
     
       1. A manufacturing method of a fiber reinforced composite material comprising:
 fixing a fiber-based material on a first mold such that an opening is defined at a first surface of the fiber-based material and such that a peripheral portion of the fiber-based material is sandwiched by the first mold to restrict movement of the fiber-based material in an extending direction thereof; 
 providing a sealed space by setting a second mold having a second surface such that the second surface faces the first surface of the fiber-based material; 
 after said providing the sealed space, filling resin into the sealed space; and 
 relatively moving said second mold toward said first mold to bring the second surface closer to the first surface, such that the fiber-based material is impregnated with the resin through the first surface of the fiber-based material, 
 wherein the first mold comprises
 a first member on which the fiber-based material is placed, 
 a second member which surrounds and directly contacts a side surface of the fiber-based material, and 
 a third member having a frame shape corresponding to a shape of the peripheral portion of the fiber-based material, a part of the third member being in direct contact with the peripheral portion of the fiber-based material; 
 
 wherein said providing a sealed space by setting a second mold comprises providing the sealed space defined by the first surface of the fiber-based material, the third member, and the second surface of the second mold. 
 
     
     
       2. The manufacturing method according to  claim 1 , wherein said filling comprises:
 reducing a pressure of the space; and 
 supplying the resin into the space after said reducing. 
 
     
     
       3. The manufacturing method according to  claim 1 , further comprising:
 curing the impregnated resin after the impregnation with the resin. 
 
     
     
       4. The manufacturing method according to  claim 3 , wherein said curing comprises:
 curing the impregnated resin by pressurizing and heating. 
 
     
     
       5. The manufacturing method according to  claim 4 , wherein said curing comprises:
 pressurizing the impregnated resin with a resin accumulator. 
 
     
     
       6. The manufacturing method according to  claim 3 , wherein said curing comprises:
 curing the impregnated resin by heating the impregnated resin. 
 
     
     
       7. The manufacturing method according to  claim 1 , wherein said fiber-based material comprises a central region and end regions on end sides of the central region,
 wherein the first surface is provided for each of the central region and the end regions, 
 wherein second mold sections of said second mold are provided on a plurality of positions to oppose to the central region and the end regions, respectively, and 
 wherein said relatively moving comprises: 
 depressing a central one of said second mold sections opposing to the central region; and 
 depressing one of said second mold sections opposing to each of the end regions after said depressing the central one of said second mold sections. 
 
     
     
       8. The manufacturing method according to  claim 7 , wherein said fiber-based material is folded between the central region and each of the end regions. 
     
     
       9. The manufacturing method according to  claim 1 , further comprising decompressing the sealed space before said filling resin into the sealed space,
 wherein said filling resin into the sealed space includes supplying the resin to the sealed space, via a resin supply line, after said decompressing, 
 wherein said resin supply line is closed during said relatively moving said second mold toward said first mold to pressurize the sealed space, 
 wherein said fixing the fiber-based material on the first mold includes arranging the third member such that the peripheral portion of the fiber-based material is sandwiched by the first member and the third member, 
 wherein the first surface is an open area in an upper surface of the fiber-based material. 
 
     
     
       10. The manufacturing method according to  claim 9 , wherein said filling comprises:
 reducing a pressure of the space; and 
 supplying the resin into the space after said reducing. 
 
     
     
       11. The manufacturing method according to  claim 9 , further comprising:
 curing the impregnated resin after the impregnation with the resin. 
 
     
     
       12. The manufacturing method according to  claim 11 , wherein said curing comprises:
 curing the impregnated resin by pressurizing and heating. 
 
     
     
       13. The manufacturing method according to  claim 12 , wherein said curing comprises:
 pressurizing the impregnated resin with a resin accumulator. 
 
     
     
       14. The manufacturing method according to  claim 11 , wherein said curing comprises:
 curing the impregnated resin by heating the impregnated resin. 
 
     
     
       15. The manufacturing method according to  claim 1 , wherein
 The first member, the second member, and the third member are all separate members; and 
 The second member is abutted against the first member, and the third member is abutted against the second member. 
 
     
     
       16. The manufacturing method according to  claim 15 , wherein a first seal is disposed between the first and second members, and a second seal is disposed between the second and third members. 
     
     
       17. The manufacturing method according to  claim 15 , wherein
 The second mold is separate from the first, second and third members of the first mold; and 
 The second mold is disposed within the frame shape of the third member. 
 
     
     
       18. The manufacturing method according to  claim 17 , wherein a seal is disposed between the second mold and the third member of the first mold.